Building panel

ABSTRACT

A building panel is provided for affixing to above-grade exterior building surfaces, the building panel comprising: opposed front and back sides generally parallel to each other; opposed top and bottom edges generally parallel to each other; a generally horizontal groove in the top edge spaced from the front and back sides; and at least one generally vertical channel extending downwardly from the generally horizontal groove through the building panel to the bottom edge at a point on the bottom edge spaced from the front and back sides. The building panel is preferably for thermal insulation and for collection and drainage of moisture from water vapour, and is preferably used in conjunction with exterior insulated finish systems.

This application is a continuation in part application of applications Ser. No. NOT YET KNOWN filed 17 Aug. 2004.

FIELD OF THE INVENTION

The present invention relates to building panels, and more particularly to building panels including a conduit system for transmission of water vapor.

BACKGROUND OF THE INVENTION

In the context of exterior building panels, the presence of moisture can lead to undesirable results. Moisture that becomes trapped within and between panels can generate rot in the substrate to which the panel is affixed, it can bleed through the panel finishing coat and discolour it, and it can even cause the panel to detach from the substrate.

Prior attempts to address this problem include Canadian Patent 1,220,041 to Larsson, which teaches a panel having drainage channels for use with subterranean wall surfaces. The channels communicate directly with the subterranean wall surface, as the channels are intended to direct water accumulation on the concrete surface away from that concrete surface. U.S. Pat. No. 6,318,041 to Stanley discloses a panel system that also employs drainage channels or conduits.

While various attempts have been made to address the problem of moisture in a variety of building panel contexts, a need has been felt for an improved means of addressing the problem in the specific context of Exterior Insulated Finish System (EIFS) technology. The EIFS system, developed in Europe in the 1950s, uses multi-layered exterior wall systems for both commercial and residential buildings, and it typically consists of an interior insulation board secured to the exterior wall surface, a reinforced base coat applied to the insulation board, and a finish coat that is both visually attractive and resistant to environmental impact. The superior energy efficiency and design flexibility of the EIFS system have resulted in growing popularity, but the presence of moisture remains a vexing problem.

SUMMARY OF THE INVENTION

According to one aspect of the present invention there is provided an insulated building panel for affixing to exterior building surfaces in rows of the panels side by side and top to bottom to form an array of the panels, the building panel comprising:

a panel body formed of an insulating foam material, the panel body having:

opposed inside and outside surfaces generally parallel to each other;

opposed top and bottom horizontal sides arranged for butting engagement with other similar panel bodies;

opposed left and right vertical sides arranged for butting engagement with other similar panel bodies;

the panel body having therein a plurality of conduits for transmission of water vapour through the array of panel bodies including at least one generally horizontal conduit spaced from the front and back surfaces and a series of transversely spaced generally vertical conduits spaced from the front and back surfaces;

the number of vertical conduits and the spacing between the vertical conduits being arranged such that water vapor migrating from the inside surface toward the outside surface is collected in the conduits prior to reaching the outside surface;

wherein the at least one horizontal conduit is defined by a groove located at one of the horizontal sides such that the conduit is defined by an open area defined between an adjacent surface of an adjacent panel on one side and a wall of the groove in the panel on the other side with the dimensions of the area so formed being sufficient to allow the passage of water vapor therethrough.

Preferably the at least one horizontal conduit is defined by a groove located at one of the horizontal sides and which has an open mouth at the side and converges inwardly toward an apex as it extends into the panel body. This is preferably the top side but may be the bottom side.

Preferably the groove has a width at its mouth in the horizontal side of the panel in a direction at right angles to the inner and outer surfaces at least equal to a width in the same direction of the vertical conduits.

Preferably the groove has a width at its mouth in the horizontal side of the panel in a direction at right angles to the inner and outer surfaces greater a width in the same direction of the vertical conduits.

Preferably that side of the groove which is adjacent the inner surface is substantially coincident with an adjacent side of the vertical conduits and that side which is adjacent the outer surface extends closer toward the outer surface than does the vertical conduit.

Preferably one half of the distance between one of the vertical conduits and the next is less than the distance between said one of the vertical conduits and the outer surface such that water vapor tends to migrate to the conduits in preference to the outer surface.

Preferably the groove and the vertical conduits are closer to the inner surface than the outer surface.

Preferably the groove is V-shaped in cross section.

Preferably the vertical conduits are rectangular in cross section.

Preferably the vertical conduits are formed by molding such that they are free from a wire cut connection to an external surface of the panel body.

Preferably each of the vertical sides includes a groove.

Preferably at least one of the vertical and horizontal sides includes a stepped joint.

Preferably the stepped joint also includes a groove.

According to a second aspect of the invention there is provided an insulated cladding system affixed to an exterior building surface comprising:

a plurality of insulated building panels affixed in rows of the panels side by side and top to bottom to form an array of the panels defining an exterior surface;

one or more exterior coating layers applied over the exterior surfaces of the panels to form an exterior finish of the building;

each building panel comprising a panel body formed of an insulating foam material, the panel body having:

opposed inside and outside surfaces generally parallel to each other;

opposed top and bottom horizontal sides arranged for butting engagement with other similar panel bodies;

opposed left and right vertical sides arranged for butting engagement with other similar panel bodies;

the panel body having therein a plurality of conduits for transmission of water vapour through the array of panel bodies including at least one generally horizontal conduit spaced from the front and back surfaces and a series of transversely spaced generally vertical conduits spaced from the front and back surfaces;

the number of vertical conduits and the spacing between the vertical conduits being arranged such that water vapor migrating from the inside surface toward the outside surface is collected in the conduits prior to reaching the outside surface;

wherein the at least one horizontal conduit is defined by a groove located at one of the horizontal sides such that the conduit is defined by an open area defined between an adjacent surface of an adjacent panel on one side and a wall of the groove in the panel on the other side with the dimensions of the area so formed being sufficient to allow the passage of water vapor therethrough.

In exemplary embodiments of the present invention, the building panel is for thermal insulation and for collection and drainage of moisture from water vapour, and the building panel is made of expanded polystyrene or polyisocyanurate. The generally horizontal groove is preferably V-shaped in cross section and configured to facilitate lateral movement of moisture from water vapour to the at least one generally vertical channel for downward flow of the moisture through the at least one generally vertical channel, and the at least one generally vertical channel is preferably rectangular in cross section. The building panel is preferably of unitary, shape-moulded construction.

By providing a building panel that can both insulate and efficiently direct moisture from water vapour away from the panels and underlying substrate, while serving the need for an even surface for application of the base and finish coats, the present invention is intended to address a pressing need in the industry.

A detailed description of an exemplary embodiment of the present invention is given in the following. It is to be understood, however, that the invention is not to be construed as limited to this embodiment.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings, which illustrate an exemplary embodiment of the present invention:

FIG. 1 is a side cross-section along line I-I in FIG. 2 of an in situ assembly of building panels according to the present invention.

FIG. 2 is a front elevation of the assembly of FIG. 1.

FIG. 3 is a plan view of a building panel according to the present invention.

FIG. 4 is a top plan view on an enlarged scale of one part of one of the panels of the previous figures.

FIG. 5 is a cross sectional view transversely through two of the panels stacked one on top of the next.

FIG. 6 is a cross sectional view similar to that of FIG. 4 showing a modified arrangement with a ship-lap connection between the panels.

DETAILED DESCRIPTION OF AN EXEMPLARY EMBODIMENT

Referring now in detail to the accompanying drawings, and particularly to FIGS. 1 and 2, there is illustrated an assembly of building panels according to the present invention, each panel being referred to generally by the numeral 10. The building panel 10 comprises opposed front and back sides 14, 16 generally parallel to each other and opposed top and bottom edges 18, 20 generally parallel to each other. Conduits for transportation of water vapor are provided in the panel including a generally horizontal V-shaped groove 22 in the top edge 18 spaced from the front and back sides 14, 16, and generally vertical channels 24 extending downwardly from the groove 22 though the building panel 10 to the bottom edge 20 at a point on the bottom edge 20 spaced from the front and back sides 14, 16. Thus the V-shaped groove is located at the surface and has an open mouth at the surface and converges inwardly and downwardly into the panel body to an apex. While FIG. 2 shows the channels 24 only in the centrally positioned building panel 10, the channels 24 are also in each of the adjacent building panels 10. The building panel 10 is of a unitary, shape-moulded construction, an advantage over traditional wire-cut construction since the vertical channels are free from the necessary wire cut entry slot from an adjacent surface of the panel.

As can be seen in FIG. 1, interior surface of the building panel 10 is includes an air barrier membrane 26 which is applied to an exterior surface 12 of a building 13 as an air/vapour barrier by an adhesive 28. In the illustrated embodiment the adhesive 28 is applied as a layer prior to positioning of the building panel 10.

Thus the exterior building surface 12 is arranged to be suitable for application of the building panels 10. Suitable substrates include but are not limited to exterior grade drywall, cement board, plywood sheathing, Dens-Glass sheathing, precast concrete, concrete block, or poured-in-place concrete. The air/vapour barrier membrane 26 is applied to the exterior building surface 12. An adhesive 28 is then applied on top of the membrane 26.

The building panels 10 are then applied over this adhesive layer 28 and secured in place thereby. For a building of four stories or greater it is advisable to use mechanical fasteners as well to secure the panels to the exterior building surface 12.

The building panels 10 are preferably arranged in the offset pattern shown in FIG. 2, a pattern well known in the art. The joints between the building panels 10 should be sealed with a suitable material (not shown) known to those skilled in the art to further enhance the insulating properties of the building panels 10.

Various methods of providing base and finishing coats (not shown) are then possible, according to the general knowledge of those skilled in the art of EIFS use.

With the building panels 10 now in place on the exterior building surface 12 and finished in a suitable manner, the groove 22 is now configured to facilitate lateral movement of water vapour to the channels 24 for downward flow of the water vapor through the channels 24. Water vapor can flow horizontally through a groove 22 and into adjacent grooves 22 as necessary, while the channels 24 then provide vertical conduits for the water vapor flowing through the grooves 22.

As is well known in the EIFS system, the exterior cladding formed by the rows and columns of panels of insulating foam are covered on the exterior surface by a first layer 30 which is a flexible mortar layer commonly having embedded therein a reinforcing fiber layer together with an exterior coating 31 of a flexible coloured material. These coatings are well known to one skilled in the art and commonly used. Different types of coating can be used.

Each of the blocks or panels forming the system therefore comprises the block as defined above which has an interior surface of the foamed insulation material indicated at 32 and an exterior surface 33. These surfaces are parallel and defined on the exterior of the insulation material which forms the block and is located therebetween. The block further includes horizontal sides 34 and 35 at the top and bottom respectively and vertical sides 35 and 36. These sides are at right angles to the front and rear surfaces so as to form a rectangular block or panel of the required thickness with each of the panels being of the same height and the same width. The panels are then arranged in rows with the top and bottom surfaces abutting and the sides surfaces also abutting.

The exterior coating surfaces 30 and 31 are applied directly onto the outside surface and there are no external sheeting elements.

The conduit system defined in the present invention is arranged to communicate moisture in the form of water vapour through the system to an exterior location. The system is not intended to nor required to communicate any form of flowing water since the amount of moisture which can penetrate is very low. The required escape of moisture is therefore also very low but, if prevented from escape, can collect over time which may be many weeks or many months leading to that moisture penetrating through the permeable foam to the exterior surfaces 30 and 31 causing damage thereto.

Differential pressures across the foam panels can cause water vapour to transfer or permeate through the structure. The water vapour tends to migrate to paths of least resistance so that, provided the conduit system provides sufficient cross sectional area of the conduits, the water vapour will tend to migrate to these conduits and pass therethrough in gaseous form in the air contained within the conduits to any exterior vent.

As best shown in FIGS. 4 and 5, the vertical conduits 16 are arranged in a series spaced along the length of the panel. Thus as shown in FIG. 5, each of the conduits 16 is rectangular in cross section and has a width W with a spacing between each conduit and the next of S. The conduits are arranged so that the distance D1 from the inner surface 32 is less than the distance D2 from the outer surface 33. Also the spacing S between each conduit and the next is arranged so that moisture tending to migrate from the inside surface 32 toward the outside surface has a shorter distance to travel to the conduit 16 than to the exterior surface 33 along the distance D2. Thus moisture at a point P in the panel tends to migrate along the distance S/2 to the conduit 16 than over the distance D2 to the exterior surface. Thus any moisture contained between the vapour barrier 26 and the panel will tend to migrate to the conduits and travel along the conduits as water vapour to an exterior vent.

In order to provide horizontal transfer of the water vapour, there are provided the grooves 22. These are preferably provided in the top surface 34 of the panel 10 but could additionally be provided in the bottom surface 35 of the panel 10A or could be provided only in the bottom surface 35 of the panel 10A. However these grooves are provided at the surface so that the groove has an open mouth 22A at which is located a portion 35A of the bottom surface 35 closing the open mouth 22A. Further the conduit is defined by portions 22B and 22C of the groove converging to an apex 22D. Thus the groove converges inwardly towards the apex as the groove extends into the body of the panel.

This arrangement allows the grooves to be formed as common action in molding the vertical conduits 16. Thus a mold which is generally rectangular in the form of the shape of the panel also includes insert elements which define the groove 22 and the channels or conduits 16. Thus a bar which is triangular in shape defines the groove 22 and the bar houses a plurality of projecting rods of rectangular cross section which define the channel 16. After the injection of the foam and the molding of the foam material into the required shape, the rods forming the channel 16 and the bar forming the groove 22 are pulled outwardly from the top face of the block to complete the molding of the hollows within the block defining the groove 22 and the channel 16. Preferably similar insert rods are provided at the opposite end forming the bottom 35 of the block 10 so that the rods forming the channel 16 extend only over one half of the length of the channels allowing them to be pulled in opposite directions from a junction point half way along the channels.

This shape-forming process in which the panels are molded including the molding of the channels and grooves provides a high efficiency forming system in which the whole structure is formed in one molding action without the necessity for cutting elements from the foam. Wire cutting systems require the necessity for an inlet and exit slot which are not necessary in the structure of the present invention.

The channels 16 are arranged in a common plane and directly aligned. The channels 16 have an inner surface 16A and an outer surface 16B. The groove 22 is arranged so that one end of the side portion 22C terminates at a position coincident with the side 16A of the channel 16. The groove 22 has a width greater than the width of the channel between the surfaces 16A and 16B. Thus the apex 22D is located at a position generally aligned with the surface 16B. Thus the portion 22B extends from the apex further outwardly of the surface 16B toward the outer surface 33. In this way, the cross sectional area of the groove 22 approximates to the cross sectional area of the rectangular channel 16 to provide approximately a similar cross sectional area for transmission of water vapour therethrough. It is clear that the amount of water vapour transmitted is generally proportional to the cross sectional area so that sufficient cross sectional area is provided both in the channel 16 and in the groove 22. Thus the groove 22 has a width at least equal to the width of the channel 16 and preferably greater in view of the triangular shape. The location for the groove at the surface allows water vapor to migrate from one vertical channel in one panel to one in the next without the necessity to align the channels in the panel assembling process.

The groove and the channels are arranged closer to the inner surface 32 than the outer surface 33 in order to ensure that moisture preferentially enters the channels rather than reaches the exterior surface 33 where damage can be caused.

As shown in FIG. 6, the top and bottom surfaces indicated at 34A and 35A include a ship-lap section generally indicated at 40 wherein there is a surface 41 which extends parallel to the inside and outside surfaces 32 and 33. Thus the surface 34A is divided into a first portion 34B and a second portion 34C and similarly the surface 35A is divided into a first portion 35B and a second portion 35C. Between these two portions is the surfaces indicated at 41. The groove indicated at 22X is formed from the portion 34C of the block 10. A further groove 22Y is formed in the surface 41 between the portions 34C and 34B. The groove 22Y thus further acts as trap for moisture tending to migrate along the surfaces 34A and 35A. This trap thus acts to collect water vapour and to transmit that water vapour to discharge. It will be noted that the groove 22X is the same width as the channel 16.

An additional groove can be provided in the vertical sides of the block again to act as a trap for any moisture migrating between the blocks.

While a particular embodiment of the present invention has been described in the foregoing, it is to be understood that other embodiments are possible within the scope of the invention and are intended to be included herein. Thus, while the embodiment illustrated in FIGS. 2 and 3 includes fifteen equally-spaced channels 24 per building panel 10, but it may be preferable to have nineteen or some other number of channels 24 depending on the application.

While particular substrates have been identified in the foregoing, it is to be understood that the application of the panel to any substrate is to be considered within the scope of the invention. Currently it is considered that the invention may not be especially useful with certain types of substrate, including oriented strand board and chipboards. It will therefore be clear to those skilled in the art that modifications of and adjustments to this invention, not shown, are possible without departing from the spirit of the invention as demonstrated through the exemplary embodiment. The invention is therefore to be considered limited solely by the scope of the appended claims. 

1. An insulated building panel for affixing to exterior building surfaces in rows of the panels side by side and top to bottom to form an array of the panels, the building panel comprising: a panel body formed of an insulating foam material, the panel body having: opposed inside and outside surfaces generally parallel to each other; opposed top and bottom horizontal sides arranged for butting engagement with other similar panel bodies; opposed left and right vertical sides arranged for butting engagement with other similar panel bodies; the panel body having therein a plurality of conduits for transmission of water vapour through the array of panel bodies including at least one generally horizontal conduit spaced from the front and back surfaces and a series of transversely spaced generally vertical conduits spaced from the front and back surfaces; the number of vertical conduits and the spacing between the vertical conduits being arranged such that water vapor migrating from the inside surface toward the outside surface is collected in the conduits prior to reaching the outside surface; wherein the at least one horizontal conduit is defined by a groove located at one of the horizontal sides such that the conduit is defined by an open area defined between an adjacent surface of an adjacent panel on one side and a wall of the groove in the panel on the other side with the dimensions of the area so formed being sufficient to allow the passage of water vapor therethrough.
 2. The building panel of claim 1 wherein the at least one horizontal conduit is defined by a groove located at one of the horizontal sides and which has an open mouth at the side and converges inwardly toward an apex as it extends into the panel body.
 3. The building panel of claim 1 wherein the groove has a width at its mouth in the horizontal side of the panel in a direction at right angles to the inner and outer surfaces at least equal to a width in the same direction of the vertical conduits.
 4. The building panel of claim 1 wherein the groove has a width at its mouth in the horizontal side of the panel in a direction at right angles to the inner and outer surfaces greater a width in the same direction of the vertical conduits.
 5. The building panel of claim 1 wherein that side of the groove which is adjacent the inner surface is substantially coincident with an adjacent side of the vertical conduits and that side which is adjacent the outer surface extends closer toward the outer surface than does the vertical conduit.
 6. The building panel of claim 1 wherein one half of the distance between one of the vertical conduits and the next is less than the distance between said one of the vertical conduits and the outer surface such that water vapor tends to migrate to the conduits in preference to the outer surface.
 7. The building panel of claim 1 wherein the groove and the vertical conduits are closer to the inner surface than the outer surface.
 8. The building panel of claim 1 wherein the groove is V-shaped in cross section.
 9. The building panel of claim 1 wherein the vertical conduits are rectangular in cross section.
 10. The building panel of claim 1 wherein the vertical conduits are formed by molding such that they are free from a wire cut connection to an external surface of the panel body.
 11. The building panel of claim 1 wherein each of the vertical sides includes a groove.
 12. The building panel of claim 1 wherein at least one of the vertical and horizontal sides includes a stepped joint.
 13. The building panel of claim 1 wherein the stepped joint also includes a groove.
 14. An insulated cladding system affixed to an exterior building surface comprising: a plurality of insulated building panels affixed in rows of the panels side by side and top to bottom to form an array of the panels defining an exterior surface; one or more exterior coating layers applied over the exterior surfaces of the panels to form an exterior finish of the building; each building panel comprising a panel body formed of an insulating foam material, the panel body having: opposed inside and outside surfaces generally parallel to each other; opposed top and bottom horizontal sides arranged for butting engagement with other similar panel bodies; opposed left and right vertical sides arranged for butting engagement with other similar panel bodies; the panel body having therein a plurality of conduits for transmission of water vapour through the array of panel bodies including at least one generally horizontal conduit spaced from the front and back surfaces and a series of transversely spaced generally vertical conduits spaced from the front and back surfaces; the number of vertical conduits and the spacing between the vertical conduits being arranged such that water vapor migrating from the inside surface toward the outside surface is collected in the conduits prior to reaching the outside surface; wherein the at least one horizontal conduit is defined by a groove located at one of the horizontal sides such that the conduit is defined by an open area defined between an adjacent surface of an adjacent panel on one side and a wall of the groove in the panel on the other side with the dimensions of the area so formed being sufficient to allow the passage of water vapor therethrough.
 15. The cladding system of claim 14 wherein the at least one horizontal conduit is defined by a groove located at one of the horizontal sides and which has an open mouth at the side and converges inwardly toward an apex as it extends into the panel body.
 16. The cladding system of claim 14 wherein the groove has a width at its mouth in the horizontal side of the panel in a direction at right angles to the inner and outer surfaces at least equal to a width in the same direction of the vertical conduits.
 17. The cladding system of claim 14 wherein the groove has a width at its mouth in the horizontal side of the panel in a direction at right angles to the inner and outer surfaces greater a width in the same direction of the vertical conduits.
 18. The cladding system of claim 14 wherein that side of the groove which is adjacent the inner surface is substantially coincident with an adjacent side of the vertical conduits and that side which is adjacent the outer surface extends closer toward the outer surface than does the vertical conduit.
 19. The cladding system of claim 14 wherein one half of the distance between one of the vertical conduits and the next is less than the distance between said one of the vertical conduits and the outer surface such that water vapor tends to migrate to the conduits in preference to the outer surface.
 20. The cladding system of claim 14 wherein the groove and the vertical conduits are closer to the inner surface than the outer surface. 